Coupled Physics-Based Modeling and in situ Experiments to quantify the deformation and failure of additively manufactured Nickel Aluminum Bronze alloys
Abstract
Approved for Public Release:Nickel aluminum bronze (NAB) is a class of alloys that is of high interest for maritime applications due to its combination of high strength and corrosion resistance. Traditionally, NAB components are manufactured through casting, however, recent advancements in additive manufacturing (AM), speci#cally Wire Arc direct energy deposition (WAAM), o#er an innovative approach to overcome the limitations of casting and reduce manufacturing time. However, the transient thermo-elastoplastic nature of AM processing introduces complexities, leading to unique microstructures after AM of NAB alloys compared to conventional techniques. This project aims to fundamentally advance the understanding of the microstructural mechanisms that govern deformation in WAAM-NAB. Large-scale three-dimensional (3D) discrete dislocation dynamics (DDD) simulations that incorporate solute strengthening, nanoprecipitate strengthening, and grain boundary strengthening models will be conducted to predict the combined e#ects of these microstructural features on the yield strength, work hardening, strain localization, and fatigue crack initiation in WAAM NAB alloys. In situ scanning electron microscopy (SEM) mechanical testing of bi-crystal WAAM NAB microcrystals will also be conducted under both monotonic and cyclic loading to experimentally validate the 3D DDD simulations and provide direct insights into dislocation activity and deformation mechanisms at phase boundaries. By quantitatively determining relationships between processing conditions, resulting microstructural attributes, and mechanical properties, this project will generate knowledge and predictive capabilities to support integrated computational materials engineering e#orts aimed at designing NAB alloys with superior strength, damage tolerance, and reliability. Overall, the proposed investigation will deliver vital new insights into the fundamental microstructural mechanisms governing dislocation plasticity, strength, ductility, strain localization, and fatigue crack initiation in these industrially important alloys fabricated through advanced additive manufacturing techniques.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Nov 08, 2024
- Source ID
- N000142412463
Entities
People
- Jaafar A El-Awady
Organizations
- Johns Hopkins University
- Office of Naval Research
- United States Navy